ABS Tone Ring Mounting Using Threaded Engagement and Coating
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Solution Overview
Problem
Existing tone ring mounting structures for antilock braking systems in heavy-duty vehicles are prone to corrosion and thermal expansion issues, leading to potential damage and system failure due to corrosion cells and rust-jacking, which complicates maintenance and reliability.
Innovation Solution
A tone ring mounting structure using threaded engagement between the tone ring and the wheel end assembly, with a corrosion-resistant coating, to prevent relative movement and corrosion, ensuring secure attachment and easy replacement, and utilizing tubular steel for the tone ring to match thermal expansion of the disc brake rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a prior art mounting structure with roll pins and wedge-shaped spacers is used to secure the tone ring to the disc brake rotor, then the tone ring is retained in place, but corrosion occurs leading to rust-jacking that damages the cantilevered lug structure and makes maintenance difficult
Solution Approach 1:
The invention extracts and eliminates the harmful elements (roll pins, wedge-shaped spacers, and resulting gaps) from the mounting structure. By using a press-fit tone ring without these additional components, the source of corrosion problems is removed, preventing rust-jacking damage to the lug structure.
Solution Approach 2:
The tone ring is integrated directly with the disc brake rotor through a press-fit connection, merging the two components into a unified assembly. This eliminates the separate fastening elements (roll pins, spacers) that created gaps and corrosion pathways, while maintaining secure retention.
2Reliability
If roll pins are used to prevent relative rotational movement of the tone ring, then the tone ring is securely retained, but the ferrous metal roll pins corrode and become difficult to remove for servicing
Solution Approach 1:
The invention removes the roll pin component entirely from the mounting structure. The press-fit connection between the tone ring and disc brake rotor provides secure retention without requiring removable fasteners, thereby eliminating the corrosion and removal difficulty issues associated with ferrous metal roll pins.
3Stability of the object's composition
If wedge-shaped spacers are used to limit axial movement between the tone ring and rotor, then the mounting is stabilized, but gaps are created that allow corrosion and road spray to accumulate
Solution Approach 1:
The invention extracts and eliminates the wedge-shaped spacers from the mounting structure. The press-fit connection provides axial stabilization without creating gaps or voids, thereby preventing the accumulation of corrosive materials such as road spray and salt.
Solution Approach 2:
By integrating the tone ring directly with the disc brake rotor through press-fit, the invention merges the components into a unified structure without intermediate spacers. This eliminates the gaps that would otherwise trap corrosive substances while maintaining stable axial positioning.
4Ease of manufacture
If the tone ring is made from sintered powdered metal, then the tone ring can be manufactured, but the manufacturing process is relatively expensive
Solution Approach 1:
The invention changes the manufacturing approach from sintered powdered metal to tubular steel material. This parameter change in material selection and formation process reduces manufacturing cost while maintaining the necessary mechanical properties and magnetic characteristics for ABS operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces corrosion and thermal expansion issues, enhancing the reliability and service life of the antilock braking system by preventing relative movement and corrosion, and simplifying maintenance by ensuring secure and easy replacement of the tone ring.
Implementation Method 1
threaded engagement of the first thread of the wheel end assembly rotatable component and the second thread of the tone ring
Implementation Method 2
A tone ring mounting structure using threaded engagement between the tone ring and the wheel end assembly, with a corrosion-resistant coating
Implementation Method 3
utilizing tubular steel for the tone ring to match thermal expansion of the disc brake rotor
Data Source
AI summary
Tone ring mounting structure for an antilock braking system comprising a wheel end assembly rotatable component having at least a first end surface and a first engagement mechanism extending radially and non-cantilevered from the rotatable component, and a tone ring having a second end surface and a second engagement mechanism extending radially from the tone ring. Connecting engagement of the first engagement mechanism of the wheel end assembly rotatable component and the second engagement mechanism of the tone ring affects movement of the second end surface in a direction toward the first end surface. The first engagement mechanism and the second engagement mechanism can be engageable threads. The first engagement mechanism can include lugs formed on the wheel end assembly rotatable component and the second engagement mechanism threads or wedge ramps engageable with the lugs. A corrosion resistant coating can be applied to components of the tone ring mounting structure.